Wireless Control Device Assembly

ABSTRACT

A control device, such as a gateway device for a wireless load control system, has a light bar extending around a periphery of an enclosure to provide feedback to a user of the load control system, as well as to provide a pleasing aesthetic effect on the gateway device. The control device may include at least one light-emitting diode mounted to a printed circuit board inside the enclosure, a control circuit mounted to the printed circuit board and operatively coupled to the light-emitting diode for controllably illuminating the light-emitting diode, and a multi-functional mounting structure for mounting the printed circuit board inside the enclosure. The mounting structure may have at least one light-pipe structure for conducting light from the at least one light-emitting diode to the light bar. The mounting structure may have an antenna-mounting structure to which an antenna of the control device may be mounted.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Patent Publication No.14/737,724, filed Jun. 12, 2015, which claims the benefit ofcommonly-assigned U.S. Provisional Application No. 62/011,881, filedJun. 13, 2014, entitled WIRELESS CONTROL DEVICE ASSEMBLY, the entiredisclosures of which are hereby incorporated by reference.

BACKGROUND Field of the Disclosure

The present disclosure relates to a load control system for controllingthe amount of power delivered to an electrical load, and moreparticularly, to a gateway or bridge device for a load control system.

Description of the Related Art

Home automation systems, which have become increasing popular, may beused by homeowners to integrate and control multiple electrical and/orelectronic devices in their house. For example, a homeowner may connectappliances, lights, blinds, thermostats, cable or satellite boxes,security systems, telecommunication systems, and the like to each othervia a wireless network. The homeowner may control these devices using acontroller or user interface provided via a phone, a tablet, a computer,and the like directly connected to the network or remotely connected viathe Internet. These devices may communicate with each other and thecontroller to, for example, improve their efficiency, their convenience,and/or their usability.

Many home automation systems require a gateway or bridge device toconnect the wireless network to the Internet. For example, if thewireless network uses a different protocol than an Internet protocol(IP), the gateway device may convert digital messages between the twoprotocols. The gateway device may comprise two radio-frequency (RF)communication circuits for communicating digital messages via thewireless network and for communicating IP messages via the Internet(e.g., using Wi-Fi technology). In addition, the gateway device maycomprise one or more electrical connectors, such as Ethernet connectors,to allow the gateway device to communicate digital messages via theInternet on a wired digital communication link (e.g., an Ethernet link).

While a gateway device is an important component of the home automationsystem, a user of the home automation system typically does not oftenphysically interact with the gateway device. Therefore, it is desirableto make the gateway device small so that the gateway device does nottake up much space in the user's home. It is also desirable for thegateway device to have an attractive appearance so that the gatewaydevice does not become an eyesore in the user's home.

SUMMARY

As described herein, a control device, such as a gateway device for awireless load control system, may have a light bar extending around aperiphery of an enclosure to provide feedback to a user of the loadcontrol system, as well as to provide a pleasing aesthetic effect on thegateway device. The control device may comprise: a printed circuitboard; an enclosure for housing the printed circuit board; alight-emitting diode mounted to the printed circuit board; and alight-pipe structure located adjacent to a side of the enclosure andconfigured to form the light bar so that the light bar extends in alateral direction along the side of the enclosure. The light-emittingdiode may be mounted to the printed circuit board adjacent to an edge ofthe printed circuit board. The light-pipe structure may be configured toconduct light from the at least one light-emitting diode in the lateraldirection along the side of the enclosure to generate the light bar.

In addition, the control device may also comprise a multi-functionalmounting structure located inside the enclosure. The multi-functionalmounting structure may be mechanically coupled between the enclosure andthe printed circuit board for mounting the printed circuit board insidethe enclosure. The light-pipe structure may be formed as part of themulti-functional mounting structure. The control device may alsocomprise an antenna for transmitting and receiving wireless signals, anda wireless communication circuit coupled to the antenna for transmittingand receiving the wireless signals. The multi-functional mountingstructure may have an antenna-mounting structure to which the antenna ismounted.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simple diagram of an example load control system forcontrolling one or more electrical loads.

FIG. 2 is a simplified block diagram of an example wireless controldevice.

FIG. 3 is a perspective view of an example wireless control device.

FIG. 4 is a rear view of the wireless control device of FIG. 3.

FIG. 5 is an exploded perspective view of the wireless control device ofFIG. 3.

FIG. 6 is a perspective view a multi-functional mounting structure ofthe wireless control device of FIG. 3.

FIG. 7 is a top view of the multi-functional mounting structure of FIG.6.

FIG. 8 is a cross-sectional side view of the multi-functional mountingstructure of FIG. 6.

FIG. 9 is a side view of an example diffuser sheet in a flattened state.

FIG. 10 is a perspective view of the diffuser sheet of FIG. 9 in afolded state.

DETAILED DESCRIPTION

FIG. 1 is a simple diagram of an example load control system 100 (e.g.,a lighting control system) for controlling the amount of power deliveredfrom an alternating-current (AC) power source to one or more electricalloads. The load control system 100 may comprise a first load controldevice, e.g., a wall-mounted dimmer switch 110, coupled in serieselectrical connection between the AC power source 102 and a firstlighting load, e.g., a first light bulb 112 installed in a ceilingmounted downlight fixture 114. In addition, the first light bulb 112 maybe installed in a wall-mounted or other lighting fixture mounted toanother surface. The dimmer switch 110 may be adapted to be wall-mountedin a standard electrical wallbox. The load control system 100 may alsocomprise a second load control device, e.g., a plug-in load controldevice 120, coupled in series electrical connection between the AC powersource 102 and a second lighting load, e.g., a second light bulb 122installed in a lamp (e.g., a table lamp 124). Specifically, the plug-inload control device 120 may be plugged into an electrical receptacle 126that is powered by the AC power source 102 and the table lamp 124 isplugged into the plug-in load control device. Alternatively, the secondlight bulb 122 may be installed in a table lamp or other lamp that maybe plugged into the plug-in load control device 120. The plug-in loadcontrol device 120 may also be implemented as a table-top load controldevice or a remotely-mounted load control device.

The dimmer switch 110 may comprise a plurality of actuators 116 (e.g.,buttons) for controlling the light bulb 112. In response to actuation ofthe actuators 116, the dimmer switch 110 may turn the light bulb 112 onand off, and increase or decrease the amount of power delivered to thelight bulb and thus increase or decrease the intensity of the light bulbfrom a minimum intensity (e.g., approximately 1%) to a maximum intensity(e.g., approximately 100%). The dimmer switch 110 may further comprise aplurality of visual indicators 118, e.g., light-emitting diodes (LEDs),arranged in a linear array and illuminated to provide feedback of theintensity of the light bulb 112. Examples of wall-mounted dimmerswitches are described in greater detail in U.S. Pat. No. 5,248,919,issued Sep. 29, 1993, entitled LIGHTING CONTROL DEVICE, and U.S. patentapplication Ser. No. 13/780,514, filed Feb. 28, 2013, entitled WIRELESSLOAD CONTROL DEVICE, the entire disclosures of which are herebyincorporated by reference.

The load control system 100 may further comprise one or more inputdevices, e.g., RF transmitters, such as a battery-powered remote controldevice 130, an occupancy sensor 140, or a daylight sensor 150. Thedimmer switch 110 and the plug-in load control device 120 may bothconfigured to receive digital messages via wireless signals, e.g.,radio-frequency (RF) signals 106, transmitted by the battery-poweredremote control device 130, an occupancy sensor 140, or a daylight sensor150. The dimmer switch 110 and the plug-in load control device 120 mayeach be configured to turn the respective light bulb 112, 122 on andoff, and to increase or decrease the intensity of the respective lightbulb in response to the received digital messages. The dimmer switch 110and the plug-in load control device 120 may both alternatively beimplemented as electronic switching devices configured to only turn onand off the respective light bulbs 112, 122.

The remote control device 130 may comprise one or more actuators 132(e.g., one or more of an on button, an off button, a raise button, alower button, and a preset button). The remote control device 130 may bea handheld remote control. The remote control device 130 may also bemounted vertically to a wall or supported on a pedestal to be mounted ona tabletop. Examples of battery-powered remote control devices aredescribed in greater detail in commonly-assigned U.S. Pat. No.8,330,638, issued Dec. 11, 2012, entitled WIRELESS BATTERY-POWEREDREMOTE CONTROL HAVING MULTIPLE MOUNTING MEANS, and U.S. PatentApplication Publication No. 2012/0286940, published Nov. 12, 2012,entitled CONTROL DEVICE HAVING A NIGHTLIGHT, the entire disclosures ofwhich are hereby incorporated by reference.

The remote control device 130 may transmit RF signals 106 in response toactuations of one or more of the actuators 132. All digital messagestransmitted by the remote control device 110 may include a command andidentifying information, for example, a serial number (e.g., a uniqueidentifier) associated with the remote control device. The remotecontrol device 130 may be assigned to the dimmer switch 110 and/or theplug-in load control device 120 during a configuration procedure of theload control system 100, such that the dimmer switch 110 and/or theplug-in load control device 120 are responsive to digital messagestransmitted by the remote control device 130 via the RF signals 106. Forexample, the RF signals 106 may be transmitted using a proprietary RFprotocol, such as the ClearConnect® protocol. Examples of methods ofassociating wireless control devices are described in greater detail incommonly-assigned U.S. Patent Application Publication No. 2008/0111491,published May 15, 2008, entitled RADIO-FREQUENCY LIGHTING CONTROLSYSTEM, and U.S. Patent Application Publication No. 2013/0214609,published Aug. 22, 2013, entitled TWO-PART LOAD CONTROL SYSTEM MOUNTABLETO A SINGLE ELECTRICAL WALLBOX, the entire disclosures of which arehereby incorporated by reference.

The occupancy sensor 140 may be configured to detect occupancy andvacancy conditions in the space in which the load control system 100 isinstalled. The occupancy sensor 140 may transmit digital messages to thedimmer switch 110 and/or the plug-in load control device 120 via the RFsignals 106 in response to detecting the occupancy or vacancyconditions. The dimmer switch 110 and/or the plug-in load control device120 may each be configured to turn on the respective light bulb 112, 122in response to receiving an occupied command, and to turn off therespective light bulb in response to receiving a vacant command.Alternatively, the occupancy sensor 140 may operate as a vacancy sensorto only turn off the lighting loads in response to detecting a vacancycondition (e.g., to not turn on the light bulbs 112, 122 in response todetecting an occupancy condition). Examples of RF load control systemshaving occupancy and vacancy sensors are described in greater detail incommonly-assigned U.S. Pat. No. 8,009,042, issued Aug. 30, 2011 Sep. 3,2008, entitled RADIO-FREQUENCY LIGHTING CONTROL SYSTEM WITH OCCUPANCYSENSING; U.S. Pat. No. 8,199,010, issued Jun. 12, 2012, entitled METHODAND APPARATUS FOR CONFIGURING A WIRELESS SENSOR; and U.S. Pat. No.8,228,184, issued Jul. 24, 2012, entitled BATTERY-POWERED OCCUPANCYSENSOR, the entire disclosures of which are hereby incorporated byreference.

The daylight sensor 150 may be configured to measure a total lightintensity in the space in which the load control system is installed.The daylight sensor 150 may transmit digital messages including themeasured light intensity to the dimmer switch 110 and/or the plug-inload control device 120 via the RF signals 106 for controlling theintensities of the respective light bulbs 112, 122 in response to themeasured light intensity. Examples of RF load control systems havingdaylight sensors are described in greater detail in commonly-assignedU.S. Pat. No. 8,410,706, issued Apr. 2, 2013, entitled METHOD OFCALIBRATING A DAYLIGHT SENSOR; and U.S. Pat. No. 8,451,116, issued May28, 2013, entitled WIRELESS BATTERY-POWERED DAYLIGHT SENSOR, the entiredisclosures of which are hereby incorporated by reference.

The load control system 100 may further comprise a gateway device 160(e.g., a bridge) configured to enable communication with a network 162,e.g., a wireless or wired local area network (LAN). The gateway device160 may be connected to a router (not shown) via a wired digitalcommunication link 164 (e.g., an Ethernet communication link). Therouter may allow for communication with the network 162, e.g., foraccess to the Internet. Alternatively, the gateway device 160 may bewirelessly connected to the network 162, e.g., using WiFi technology. Anexample of the gateway device 100 is described in greater detail incommonly-assigned U.S. Patent Application Publication No. 2014/0052783,published Feb. 20, 2014, entitled WIRELESS BRIDGE FOR FACILITATINGCOMMUNICATION BETWEEN DIFFERENT NETWORK, and U.S. patent applicationSer. No. 14/578,602, filed Dec. 22, 2014, entitled WIRELESS LOAD CONTROLSYSTEM, the entire disclosures of which are hereby incorporated byreference.

The gateway device 160 may be configured to transmit RF signals 106 tothe dimmer switch 110 and/or the plug-in load control device 120 (e.g.,using the proprietary protocol) for controlling the respective lightbulbs 112, 122 in response to digital messages received from externaldevices via the network 162. The gateway 160 may be configured toreceive RF signals 106 from the dimmer switch 110, the plug-in loadcontrol device 120, the remote control device 130, the occupancy sensor140, and/or the daylight sensor 150 (e.g., using the proprietaryprotocol), and to transmit digital messages via the network 162 forproviding data (e.g., status information) to external devices. Thegateway device 160 may operate as a central controller for the loadcontrol system 100, or may simply relay digital messages between thecontrol devices of the load control system and the network 162.

The load control system 100 may further comprise a network device 170,such as, a smart phone (e.g., an iPhone® smart phone, an Android® smartphone, or a Blackberry® smart phone), a personal computer, a laptop, awireless-capable media device (e.g., MP3 player, gaming device, ortelevision), or a tablet device, (e.g., an iPad® hand-held computingdevice), a Wi-Fi or wireless-communication-capable television, or anyother suitable Internet-Protocol-enabled device. The network device 170may be operable to transmit digital messages in one or more InternetProtocol packets to the gateway device 160 via RF signals 108 eitherdirectly or via the network 162. For example, the network device 170 maytransmit the RF signals 108 to the gateway device 160 via a Wi-Ficommunication link, a Wi-MAX communications link, a Bluetooth®communications link, a near field communication (NFC) link, a cellularcommunications link, a television white space (TVWS) communication link,or any combination thereof. Examples of load control systems operable tocommunicate with network devices on a network are described in greaterdetail in commonly-assigned U.S. Patent Application Publication No.2013/0030589, published Jan. 31, 2013, entitled LOAD CONTROL DEVICEHAVING INTERNET CONNECTIVITY, the entire disclosure of which is herebyincorporated by reference.

The network device 170 may have a visual display 172, which may comprisea touch screen having, for example, a capacitive touch pad displacedovertop the visual display, such that the visual display may displaysoft buttons that may be actuated by a user. The network device 170 maycomprise a plurality of hard buttons, e.g., physical buttons (notshown), in addition to the visual display 172. The network device 170may download a product control application for allowing a user of thenetwork device to control the lighting control system 100. In responseto actuations of the displayed soft buttons or hard buttons, the networkdevice 170 may transmit digital messages to the gateway device 160through the wireless communications described herein. The network device170 may transmit digital messages to the gateway device 160 via the RFsignals 108 for controlling the dimmer switch 110 and/or the plug-inload control device 120. The gateway 160 may be configured to transmitRF signals 108 to the network device 170 in response to digital messagesreceived from the dimmer switch 110, the plug-in load control device120, the remote control device 130, the occupancy sensor 140, and/or thedaylight sensor 150 (e.g., using the proprietary protocol) fordisplaying data (e.g., status information) on the visual display 172 ofthe network device.

The operation of the load control system 100 may be programmed andconfigured using the network device 170. An example of a configurationprocedure for a wireless load control system is described in greaterdetail in commonly-assigned U.S. patent application Ser. No. 13/830,237,filed Mar. 14, 2013, entitled COMMISSIONING LOAD CONTROL SYSTEMS, theentire disclosure of which is hereby incorporated by reference.

The gateway device 160 may also be configured to transmit digitalmessages to the dimmer switch 110 and/or the plug-in load control device120 for controlling the respective light bulbs 112, 122 according to atimeclock schedule, which may be stored in a memory in the gatewaydevice. The timeclock schedule may include a number of timeclock events,each having an event time and a corresponding command or preset. Thegateway device 160 may be configured to keep track of the present timeand day and to transmit the appropriate command or preset at therespective event time of each timeclock event.

The gateway device 160 may be configured to obtain the present time anddate from the Internet via the network 162, e.g., by communicating witha time server, such as, the National Institute of Standards andTechnology server, which has a Domain Name System (DNS) address oftime.nst.gov. For example, the gateway device 160 may obtain the presenttime and date when the gateway device is first powered on or reset, andmay re-synchronize the time and day periodically, e.g., each night. Thegateway device 160 may also be configured to obtain the present time anddate from the network device 170. For example, the network device 170may be configured to transmit the present time and date to the gatewaydevice 160 via the RF signals 108 whenever a user logs into the productcontrol application running on the network device.

The gateway device 160 may not have a battery backup for maintaining thepresent time and date, but may re-synchronize the present time and dateas discussed above. If the gateway device 160 “loses” the present timeand date, the gateway device is configured to disable the timeclockschedule. For example, the gateway device 160 may lose the present timeand date if the connection to the Internet via the network 162 is notavailable and the gateway device 160 is reset. When the gateway device160 is able to obtain the present time and date once again (e.g., viathe Internet or the network device 170), the gateway device isconfigured to enable the timeclock schedule.

The load control system 100 may comprise one or more other types of loadcontrol devices, such as, for example, a dimming ballast for driving agas-discharge lamp; a light-emitting diode (LED) driver for driving anLED light source; a dimming circuit for controlling the intensity of alighting load; a screw-in luminaire including a dimmer circuit and anincandescent or halogen lamp; a screw-in luminaire including a ballastand a compact fluorescent lamp; a screw-in luminaire including an LEDdriver and an LED light source; an electronic switch, controllablecircuit breaker, or other switching device for turning an appliance onand off; a controllable electrical receptacle or controllable powerstrip for controlling one or more plug-in loads; a motor control unitfor controlling a motor load, such as a ceiling fan or an exhaust fan; adrive unit for controlling a motorized window treatment or a projectionscreen; motorized interior or exterior shutters; a thermostat for aheating and/or cooling system; a temperature control device forcontrolling a setpoint temperature of an HVAC system; an airconditioner; a compressor; an electric baseboard heater controller; acontrollable damper; a variable air volume controller; a fresh airintake controller; a ventilation controller; a hydraulic valves for useradiators and radiant heating system; a humidity control unit; ahumidifier; a dehumidifier; a water heater; a boiler controller; a poolpump; a refrigerator; a freezer; a television or computer monitor; avideo camera; an audio system or amplifier; an elevator; a power supply;a generator; an electric charger, such as an electric vehicle charger;and an alternative energy controller.

In addition, the load control system 100 may comprise other types ofinput device, such as, for example, temperature sensors, humiditysensors, radiometers, cloudy-day sensors, pressure sensors, smokedetectors, carbon monoxide detectors, air-quality sensors, motionsensors, security sensors, proximity sensors, fixture sensors, partitionsensors, keypads, kinetic or solar-powered remote controls, key fobs,cell phones, smart phones, tablets, personal digital assistants,personal computers, laptops, timeclocks, audio-visual controls, safetydevices, power monitoring devices (such as power meters, energy meters,utility submeters, utility rate meters), central control transmitters,residential, commercial, or industrial controllers, or any combinationof these input devices.

FIG. 2 is a simplified block diagram of an example wireless controldevice, e.g., a gateway device 200, which may be deployed as, forexample, the gateway device 160 of the load control system 100 shown inFIG. 1. The gateway device 200 may comprise a control circuit 210, whichmay include one or more of a processor (e.g., a microprocessor), amicrocontroller, a programmable logic device (PLD), a field programmablegate array (FPGA), an application specific integrated circuit (ASIC), orany suitable processing device. The gateway device 200 may comprise anetwork communication circuit 212 coupled to a network connector 214(e.g., an Ethernet jack), which is adapted to be connected to a wireddigital communication link (e.g., an Ethernet communication link) forallowing the control circuit 210 to communicate with network devices ona network (e.g., a local area network, such as the network 162 shown inFIG. 1). Alternatively, the network communication circuit 212 may beconfigured to be wirelessly connected to the network, e.g., using WiFitechnology to transmit and receive RF signals (e.g., the RF signals 108shown in FIG. 1).

The gateway device 200 may further comprise a wireless communicationcircuit 216, for example, including an RF transceiver coupled to anantenna for transmitting and receiving RF signals (e.g., the RF signals106 shown in FIG. 2) using a proprietary protocol (e.g., theClearConnect® protocol). The control circuit 210 may be coupled to thewireless communication circuit 216 for transmitting digital messages viathe RF signals 106, for example, to control the dimmer switch 110 and/orthe plug-in load control device 120 in response to digital messagesreceived via the network communication circuit 212. The control circuit210 may also be configured to receive digital messages from, forexample, the dimmer switch 110, the plug-in load control device 120, theremote control device 130, the occupancy sensor 140, and/or the daylightsensor 150. For example, the control circuit 210 may be configured toreceive a digital message including the intensity of a lighting load(e.g., one of the light bulbs 112, 122 of the load control system 100shown in FIG. 1), and to transmit a digital message including theintensity of the lighting load to the network device 170 for displayingthe intensity on the visual display 172.

The control circuit 210 may be coupled to a memory 218 for storage ofoperational characteristics of the gateway device 200 and/or the loadcontrol system 100. The memory 218 may be implemented as an externalintegrated circuit (IC) or as an internal circuit of the control circuit210. The control circuit 210 may be responsive to an actuator 220 forreceiving a user input. For example, the control circuit 210 may beoperable to associate the gateway device 210 with one or more controldevices of the load control system 100 in response to actuations of theactuator 220 during a configuration procedure of the load controlsystem. The control circuit 210 may store the serial numbers of thecontrol devices to which the gateway device 200 is associated in thememory 218. The gateway device 200 may comprise additional actuators towhich the control circuit 210 is responsive.

The control circuit 210 may be operable to illuminate a visual indicator222 to provide feedback to a user of the load control system. Forexample, the control circuit 210 may blink or strobe the visualindicator 222 to indicate a fault condition. In addition, the controlcircuit 210 may be operable to illuminate the visual indicator 222different colors to indicator different conditions or states of thegateway device 200. The visual indicator 220 may be illuminated by, forexample, one or more light-emitting diodes (LEDs). Alternatively, thegateway device 200 may comprise additional visual indicators.

The gateway device 200 may further comprise a power supply 224 forgenerating a DC supply voltage V_(CC) for powering the control circuit210, the network communication circuit 212, the wireless communicationcircuit 216, the memory 218, and other circuitry of the gateway device.The power supply 224 may be coupled to a power supply connector 226(e.g., a USB port) for receiving a supply voltage (e.g., a DC voltage)and for drawing current from an external power source.

FIG. 3 is a perspective view and FIG. 4 is a rear view of an examplewireless control device, e.g., a gateway device 300, which may bedeployed as, for example, the gateway device 160 of FIG. 1 or thegateway device 200 of FIG. 2. The gateway device 300 may comprise anenclosure having an upper portion 310 and a lower portion 312. Theenclosure may have a rectangular shape with four substantially planarsides 314 (e.g., each having a length of approximately 2.75 inches). Thegateway device 300 may further comprise a visual indicator, e.g., alight bar 316, extending around the periphery of the enclosure betweenthe upper portion 310 and the lower portion 312. For example, the lightbar 316 may extend in a lateral direction A along a front side 314′ ofthe enclosure as shown in FIG. 3. The light bar 316 may extend in atransverse direction T along the two sides 314 of the enclosure that areadjacent to the first side 314′. The gateway device 300 may beconfigured to illuminate the light bar 316 to provide feedback to a userof the load control system of the gateway device (e.g., as the controlcircuit 210 illuminates the visual indicator 222), as well as to providea pleasing aesthetic effect on the gateway device.

The gateway device 300 may be configured to transmit and receivewireless signals (e.g., the RF signals 106 shown in FIG. 1) with controldevices of a load control system (e.g., the load control system of FIG.1). The gateway device 300 may comprise an actuator 318 (e.g., theactuator 220 of the gateway device 200 of FIG. 2) that may be actuated,for example, to associate the gateway device with the control devices ofthe load control system. The gateway device 300 may comprise a networkconnector 320 (e.g., an Ethernet jack, such as the network connector 214of the gateway device 200 of FIG. 2) for allowing the gateway device 300to be connected to a network (e.g., the network 162). The gateway device300 may further comprise a power supply connector 322 (e.g., a USB port,such as the power supply connector 226 of the gateway device 200 of FIG.2) adapted to be coupled to an external power source for powering thegateway device 300.

FIG. 5 is an exploded perspective view of the gateway device 300. Thegateway device 300 may comprise a printed circuit board (PCB) 330 onwhich the electrical circuitry of the gateway device may be mounted(e.g., the electrical circuitry shown in FIG. 2). The actuator 318, thenetwork connector 320, and the power supply connector 322 may be mountedto the printed circuit board 330. The gateway device 300 may include anRF shield 332 surrounding most of the electrical circuitry on theprinted circuit board 330.

The gateway device 300 may further comprise a multi-functional mountingstructure 340. FIG. 6 is a perspective view and FIG. 7 is a top view ofthe multi-functional mounting structure 340. FIG. 8 is a cross-sectionalside view of the multi-functional mounting structure 340 taken throughthe center of the mounting structure as shown in FIG. 7. Themulti-functional mounting structure 340 may have four sides that arearranged adjacent the four planar sides 314 of the enclosure. Themulti-functional mounting structure 340 may comprise legs 342 that mayextend in a longitudinal direction L and may rest on the printed circuitboard 330 when the gateway device 300 is assembled. The printed circuitboard 330 may be fixedly connected to the multi-functional mountingstructure 340 via a screw 344 received through an opening (not shown) inan additional leg 346 (FIG. 6) of the mounting structure. Themulti-functional mounting structure 340 may be mounted to the upperportion 310 of the enclosure, for example, via heat stakes (not shown)received through openings in various projections 345 of themulti-functional mounting structure.

The gateway device 300 may further comprise a light diffuser 348captured between the upper portion 310 and the lower portion 312 of theenclosure when the gateway device 300 is assembled. The light diffuser348 may be formed as part of the enclosure, e.g., as part of the lowerportion 312. The upper portion 310 may be fixedly connected to the lowerportion 312 via four screws 350 received through openings 352 (FIG. 7)in the legs 342 of the mounting structure 340. A plurality of rubberpads 354 may be adapted to be placed over openings (not shown) in thelower portion 312 through which the screws 350 extend.

The gateway device 300 may further comprise an antenna 356 (e.g., ahelical antenna) that may be a part of a wireless communication circuitmounted on the printed circuit board 330 (e.g., the wirelesscommunication circuit 216 of the gateway device 200 shown in FIG. 2). Asshown in FIG. 4, the antenna 356 may comprise an electrical wire woundin the form of a helix. The multi-functional mounting structure 340 maycomprise a cylindrical antenna-mounting portion 358 extending along thelongitudinal direction L. The antenna 356 may be mounted around thecylindrical antenna-mounting portion 358 of the multi-functionalmounting structure 340 in a specific orientation. During manufacturingof the gateway device 300, the antenna 356 may be mounted around thecylindrical structure 358 before the printed circuit board 330 isconnected to the mounting structure 340 and the antenna is electricallycoupled to the printed circuit board. The cylindrical structure 358 maysimplify the assembly process and ensure that the antenna 356 ispositioned corrected in the fully-assembled product. The cylindricalstructure 358 may also operate as one of the projections 345 formounting the multi-functional mounting structure 340 to the upperportion 310 of the enclosure.

The gateway device 300 may comprise a three light-emitting diodes (LEDs)362 for illuminating the light bar 316 along the three respective sides314 of the enclosure. To provide a uniform distribution of light acrossthe length of the light bar 316 on each side 314 of the enclosure, thegateway device 300 may comprise a respective light-pipe structure forconducting light emitted by each LED 362 to the light bar 316 along therespective side of the enclosure. If the respective light-pipe structurewere to extend in a single plane from the LED 362 to the light bar 316,the light-pipe structure would need to be approximately as long as thelength of the light bar 316 along the respective side of the enclosurein order to uniformly spread the illumination along the length of thelight bar. In other words, to uniformly illuminate the light bar 316along the front side 314′ of the enclosure (which has a length ofapproximately 2.75 inches), a planar light-pipe structure would need tobe approximately 2.75 inches long. Since the four sides 314 of theenclosure have the same length and gateway device 300 comprises manyother internal components, a planar light-pipe structure would beunsuitable for use in the gateway device 300 shown in FIGS. 3-8.

Accordingly, the gateway device 300 may further comprise a plurality ofcomplex light-pipe structures 360 for forming the light bar 316 betweenthe upper and lower portions 310, 312 of the enclosure. The light-pipestructures 360 may be formed as part of the multi-functional mountingstructure 340 and may surround three sides of the mounting structure340. Each light-pipe structure 360 may extend for the full width of eachside 314 of the enclosure of the gateway device 300 (e.g., in thelateral direction A along the front side 314′ or in the transversedirection T along the adjacent sides). Each light pipe structure 360 maycomprise a top side 364 adjacent to the light bar 316 along therespective side 314 of the enclosure. Each light-pipe structure 360 mayoperate to spread the illumination from the adjacent LED 362 along anemitter surface 365 adjacent the top side 364 and thus along the lengthof the light bar 316 as the light bar extends across the respective side314 of the enclosure (e.g., in the lateral direction A along the frontside 314′ or in the transverse direction T along the adjacent sides).

Each LED 362 may be mounted along three respective edges of the printedcircuit board 330 at approximately the center of the adjacent light-pipestructure 360. For example, when the printed circuit board 330 ismounted inside of the enclosure, the center of the each LED 362 may belocated approximately 0.135 inches from an adjacent inside surface 312′(FIG. 5) of the lower portion 312 of the enclosure (e.g., as measuredalong the transverse direction T on the front side 314′ or along thelateral direction A on the adjacent sides). Each LED 362 may be mountedto the printed circuit board 330 below the respective light-pipestructure 360 and may be configured to emit light in the longitudinaldirection L up towards the light-pipe structure. As shown in FIG. 8,each light-pipe structure 360 may comprise a lower recess 366 in whichthe respective LED 362 on the printed circuit board 330 may be located.The lower recess 366 may be located at the center of the light-pipestructures 360 and may operate as a lens to direct the illuminationemitted from the respective LED 362 along the length of the light-pipestructure 360 in both directions away from the LED (e.g., in the lateraldirection A along the front side 314′ or in the transverse direction Talong the adjacent sides). Each light-pipe structure 360 may furthercomprise an upper recess 368, which may be located above the lowerrecess 366 and may reflect the illumination (that is not directed by thelower recess 366) along the length of the light-pipe structure 360 inboth directions away from the LED (e.g., in the lateral direction Aalong the front side 314′ or in the transverse direction T along theadjacent sides).

Each light-pipe structure 360 may operate to uniformly distribute thelight from the respective LED 362 to the emitter surface 365 adjacentthe top side 364 of the light-pipe structure. The emitter surfaces 365may be located on the external sides of light pipe structure 365 (asshown in FIG. 6) and may be, for example, textured to uniformly dispersethe illumination. As shown in FIG. 8, each light-pipe structure 360 mayget narrower (e.g., narrower in the longitudinal direction L) as thelight-pipe structure extends away from the lower recess 366 in thecenter towards the ends of the light-pipe structure (e.g., in thelateral direction L along the first side 314′). As shown in FIG. 7, eachlight-pipe structure 360 may also get narrower in the transversedirection T (along the first side 314′) and in the lateral direction A(along the adjacent sides) as the light-pipe structure extends away fromthe lower recess 366 in the center towards the ends of the light-pipestructure. The illumination at the emitter surface 365 adjacent the topside 364 of each light-pipe structure 360 may be conducted through thelight diffuser 348 (e.g., through the light diffuser in the transversedirection T on the front side 314′ of the enclosure) to form the lightbar 316 between the upper portion 310 and the lower portion 312 of theenclosure when the gateway device 300 is fully assembled. The upperrecess 368 may also soften the illumination at the emitter surface 365adjacent the top side 364 of each light-pipe structure 360 immediatelyabove the respective LED 362.

Accordingly, the light pipe structures 360 and the light diffuser 348may operate to receive light emitted from the LEDs 362 in a firstdirection (e.g., in the longitudinal direction L), to direct the lightalong the sides 314 of the enclosure in a second direction (e.g., in thelateral direction A along the first side 314′), and to direct light outfrom inside of the enclosure in a third direction (e.g., in thetransverse direction T through the first side 314′) to form the lightbar 316 around the enclosure. The light pipe structures 360 and thelight diffuser 348 may allow the LEDs 362 to be mounted along the edgesof the printed circuit board 330 thus avoiding planar light-pipestructures and saving space inside of the gateway device 300.

The gateway device 300 may further comprise an additional diffusermaterial located between the light diffuser 348 and the light-pipestructures 360 of the multi-functional mounting structure 340. FIG. 9 isa side view of an example diffuser sheet 370 (e.g., a diffuser strip) ina flattened state. FIG. 10 is a perspective view of the diffuser sheet370 in a folded state. The diffuser sheet 370 may be configured to befolded along lines 372 into the folded state shown in FIG. 10. Thediffuser sheet 370 may comprise, for example, strip of clear plasticfilm that is printed with multiple fade patterns 374. When in the foldedstate, the diffuser sheet 370 may be located (e.g., slid) between aninner surface 349 of the light diffuser 348 and the light-pipestructures 360 of the multi-functional mounting structure 340 (e.g., inthe configuration shown in FIG. 5). The diffuser sheet 370 may comprisea notch 376 that is configured to align with a tab (not shown) in theupper portion 310 of the enclosure.

The diffuser sheet 370 may further balance the intensity of the lightbar 316 along the length of the light bar on each of the side 314 of theenclosure to provide to a uniform illumination. When the diffuser sheet370 is installed in the gateway device 300, the fade patterns 374 mayline up with hot spots generated by the light-pipe structures 360, e.g.,to attenuate the light conducted to the light diffuser 348 adjacent thehot spots on the light-pipe structures 360. The fade patterns 374 may belocated near the locations of the LEDs 362. For example, the multiplefade patterns 374 may each be the same pattern with one fade patternalong each of the sides 314 of the enclosure adjacent the respective LED362. However, the internal structure of the gateway device 300 may causethe hot spots to be generated at different locations along the light bar316 on each of the side 314 of the enclosure. For example, the hot spotsmay be generated on the light bar 316 dues to reflections of light offof the RF shield 332, light being blocked by other structures, and/ordifferences in the light-pipe structures 360 because of features of themulti-functional mounting structure 340, such as the various projections345 of the multi-functional mounting structure. Therefore, the multiplefade patterns 374 may be different patterns and may be located atdifferent locations on the diffuser strip 370 along the sides 314 of theenclosure as shown in FIG. 9. In addition, the diffuser strip 370 maycomprise multiple fade patterns along each of the sides 314 of theenclosure as shown in FIG. 9.

1. (canceled)
 2. A light diffusion system, comprising: a light-pipestructure having a length, an upper surface and a lower surface formingan angle with the upper surface such that the light-pipe structuretapers from a relatively thicker central portion to relatively thinnerterminal portions at each end of the length; a light diffuser having afirst portion and a second portion optically coupled to and disposedorthogonal to the first portion; wherein the first portion of the lightdiffuser disposed proximate the upper surface of the light-pipestructure such that, in operation, at least a portion of the lightconveyed by the light pipe structure exits radially outward from thesecond portion of the light diffuser.
 3. The system of claim 2 whereinthe light diffuser comprises a light diffuser in which the first portionand the second portion optically couple to provide a light diffuserhaving a “T”-shaped transverse cross-section.
 4. The light diffusionsystem of claim 2, the light-pipe structure further comprising: a firstrecess formed in the lower surface of the central portion of thelight-pipe structure, the first recess to accept at least a partialinsertion of a light source, the first recess to provide a plurality oflens surfaces through which light from the light source may enter thelight-pipe structure.
 5. The light diffusion system of claim 4, thelight-pipe structure further comprising: a second recess formed in theupper surface of the central portion of the light-pipe structure,opposite the first recess, the second recess to provide a plurality ofreflective surfaces to reflect at least a portion of the light from thelight source into the light-pipe structure.
 6. The light diffusionsystem of claim 2, further comprising: a diffuser sheet disposed betweenthe light diffuser and the light-pipe structure.
 7. The light diffusionsystem of claim 6 wherein the diffuser sheet comprises a diffuser sheetthat includes one or more fade patterns.
 8. The light diffusion systemof claim 2 wherein the light diffuser comprises a three-sided “U” shapedstructure.
 9. The light diffusion system of claim 8 wherein thelight-pipe structure comprises a plurality of light-pipe structuresegments, each of the light-pipe structure segments having the uppersurface and the lower surface forming the angle with the upper surfacesuch that the light-pipe structure tapers from the relatively thickercentral portion to the relatively thinner terminal portions at each endof the length.
 10. The light diffusion system of claim 9 wherein theplurality of light-pipe structure segments includes three light-pipestructure segments, each of the light-pipe structure segments disposedproximate a respective first portion of each side of the three-sided“U”-shaped light diffuser structure.
 11. A light diffusion method,comprising: disposing a light diffuser having a first portion and asecond portion optically coupled to and disposed orthogonal to the firstportion proximate a light-pipe structure having a length, an uppersurface and a lower surface forming an angle with the upper surface suchthat the light-pipe structure tapers from a relatively thicker centralportion to relatively thinner terminal portions at each end of thelength; wherein the first portion of the light diffuser is disposedproximate the upper surface of the light-pipe structure such that, inoperation, at least a portion of the light conveyed by the light pipestructure exits radially outward from the second portion of the lightdiffuser.
 12. The light diffusion method of claim 11, furthercomprising: disposing a light source at least partially in a firstrecess formed in the lower surface of the central portion of thelight-pipe structure, the first recess to accept at least a partialinsertion of a light source, the first recess to provide a plurality oflens surfaces through which light from the light source may enter thelight-pipe structure.
 13. The light diffusion method of claim 11,further comprising: disposing a diffuser sheet between the lightdiffuser and the light-pipe structure.
 14. The light diffusion method ofclaim 13 wherein disposing the diffuser sheet between the light diffuserand the light-pipe structure further comprises: disposing a diffusersheet that includes one or more fade patterns between the light diffuserand the light-pipe structure.
 15. The light diffusion method of claim11: wherein the light diffuser comprises a three-sided “U” shapedstructure; wherein the light-pipe structure includes three light-pipestructure segments, each of the light-pipe structure segments having theupper surface and the lower surface forming the angle with the uppersurface such that the light-pipe structure tapers from the relativelythicker central portion to the relatively thinner terminal portions ateach end of the length; and wherein disposing a light diffuser proximatea light-pipe structure further comprises: disposing each of thelight-pipe structure segments proximate a respective side of thethree-sided “U”-shaped light diffuser structure.
 16. The light diffusionmethod of claim 11, further comprising: disposing at least a portion ofthe second portion of the light diffuser between an upper housingportion and a lower housing portion such that at least a portion of thesecond portion of the light diffuser forms at least a portion of anexternal surface of a housing formed by affixing the upper housingportion to the lower housing portion.